Relay construction



July 16, 1963 R. B. FARMER RELAY CONSTRUCTION Original Filed Jan. 16.1958 52 INVENTOR. 05156 5. FAR/WEE BYW M' 4 rrozAle/s.

States 13 Claims. (Cl. 200*87) iter- This invention relates to a relayand, more particularly, to a new and improved miniature relay havingdynamically balanced operating characteristics. This application is acontinuation of the copending application of Robert B. Farmer, SerialNo. 709,375, filed January 16, 1958, now abandoned.

With the reduction in the physical size of electronic equipment providedby the use of smaller electronic devices, such as miniature vacuum tubesand transistors, and by the use of printed circuit techniques, forinstance, it has become necessary to reduce the physical size ofelectromagnetic switching devices which often form a part of thisequipment The miniaturization of electronic equipment is particularlyimportant in mobile applications, such as equipment adapted to be usedin aircraft. In these applications, the components are subjected tosevere conditions of vibration and shock and thus, the miniaturizedcomponents must have stable operating characteristics which are notadversely affected by these factors.

Accordingly, one object of the present invention is to provide a new andimproved miniature relay.

Another object is to provide a relay including new and improvede'lectromagnetically operated means for actuating a contact assembly.

A further object is to provide new and improved means for mounting theoperating coil of an electromagnetic switch on a supporting frametherefor.

A still further object is to provide new and improved means for mountinga relay operating coil, which means also provides a portion of themagnetic circuit for the relay.

In accordance with these and many other objects, an embodiment of thepresent invention comprises a coil structure having an axially extendingopening in which are slidably mounted, in parallel relationship, a pairof magnetic core elements. The two core elements are formed withenlarged end portions which are disposed at opposite ends of the coilstructure to be received within enlarged slots formed in a pair ofspaced end walls of a supporting frame, the other ends of the two coreelements being received within smaller slots formed contiguous to theenlarged slots. The enlarged head portions on the oppositely extendingcore elements thus provide means for locating the operating coilassembly in a predetermined position on the supporting frame and alsoprovide enlarged pole pieces forming a portion of the magnetic circuitfor the relay.

To provide a means for actuating a plurality of spring assembliescarried on a header plate to which the support ing frame is secured, therelay includes a substantially rectangular armature which is pivotallymounted on the supporting frame for movement about an axis perpendicularto the core elements. The armature is provided with a centrally disposedopening through which the core elements and the coil assembly extend sothat spaced intermediate portions of the armature are disposedimmediate- 1y adjacent the enlarged portions of the core elements whichprovide the pole pieces. A pair of actuator arms secured to the armatureat points spaced equally, from the axis of rotation thereof actuates thespring assemblies when the coil assembly is energized to pivot thearmature 3 ,698 1 Patented July 16, 1963 2 into engagement with theenlarged end portions of the core elements.

Many other objects and advantages of the present invention will becomeapparent from the following detailed description when taken inconjunction with the following drawings wherein:

FIG. 1 is an exploded view showing a minature relay embodying thepresent invention removed from a protective dust cover or housingtherefor;

FIG. 2 is an enlarged sectional 22 in FIG. 1;

FIG. 3 is a sectional view taken along line 3-3 in FIG. 2 assuming thatthe entire relay construction is shown therein;

FIG. 4 is a sectional view taken along line 44 in FIG. 2 again assumingthat the entire relay construction is shown therein; and,

FIG. 5 is an exploded perspective view of a field structure andoperating coil mounting assembly included in the relay of the presentinvention.

Referring now more specifically to the drawings, therein is shown arelay, indicated generally as 10, embodying the present invention andwhich includes a coil assembly 12 including an axially extendingopening. A core assembly 14, which is slidably mounted in the opening inthe coil assembly 12, is carried on a supporting frame 16 to provide thesole support for the coil assembly 12. The core assembly 14 includesenlarged end portions which space the coil assembly 12 relative to theframe 16 and which also provide pole pieces. An armature 18, which issubstantially rectangular in configuration and which is provided with acentrally disposed opening, is pivotally mounted on the frame 16 formovement about an axis normal to the core assembly 14. The core assembly14 and the coil assembly 12 extend through the opening in the armature18 so that opposite ends of the armature 18 are disposed adjacentopposite ends of the core assembly 14 on opposite sides thereof. Whenthe coil assembly 12 is energized, the armature 18 is pivoted in aclockwise direction (FIG. 3) so that the opposite ends thereof movetoward the core assembly 14. In so moving, the armature 18 actuates acontact spring assembly 20 which is carried on a header plate 22 towhich the supporting frame 16 is connected. A dust cover 24 is providedfor enclosing the relay assembly 10.

Referring now more specifically to the coil assembly 1 2, this comprisesa dielectric coil bobbin 26 having a pair of end walls 28 and Sil and onwhich an operating coil 32 is wound. The coil bobbin 26 defines anaxially extending opening 34- which is substantially rectangular incrosssection.

The core assembly 14, in addition to providing a portion of the magneticcircuit for the relay 10 in affording pole pieces spaced axially of thecore assembly 12, also provides the sole means for supporting the coilassembly 12 in a proper position on the frame 16. The core assembly 14includes a pair of magnetic and somewhat T- shaped elements 36 and 38,each having an enlarged head portion 360 or 38a of somewhat rectangularconfiguration. In order to detachably mount the coil assembly 12 on theframe 16, the assembly 12 is placed within the housing 16 between a pairof spaced end walls 16a and 16b. The core element 36 is then insertedinto the opening 34 so that the enlarged end 3641 is received within anenlarged slot 40 (FIG. 5) formed in the sidewall 16b and so that theother end of the element-36 is received within a smaller slot 42 whichis formed within the end wall in alignment with the slot 40. The secondcore element 38 is then inserted into the opening '34 in the coil bobbin26 so that the enlarged end 38a thereof is positioned within an enlargedslot 44- in the end wall 16a and so that the oppposite end of theelement 38 is disposed view taken along line in a smaller slot 46 whichis formed in the end wall 16b in alignment with the slot 44. The widthand height of the core elements 36 and 38 are such that these elementstightly engage the inner surfaces of the bobbin 26 which define theopening 34. Further, the enlarged portions 36a and 38a engage the endplates 28 and 30 of the bobbin 26 so that the coil assembly 12 ispositively held in a centrally disposed position within the supportingframe 16. When the coil assembly 12 is to be removed from the relay 10,it can easily be disassembled merely by pressing the small ends of theelements 36 and 38 at opposite ends of the frame 16 and removing themfrom the opening 34 in the coil bobbin 26.

The enlarged portions 36a and 380, which are disposed on laterallyopposite sides of the core assembly 14, provide pole pieces toward whichrecessed portions 18a and 18b on the armature 18 move when the coilassembly 12 is energized. To provide a compact assembly including thearmature 18 and the coil assembly 12, an opening 47 is formed in thearmature 18 through which the coil assembly 12 and the core assembly 14extend. The armature 18 is pivotally mounted on the frame 16 forrotation about an axis normal to the coil assembly 12 and the coreassembly 14 by a pair of pins 48 and 50 which are formed integral withthe armature 18. The axis defined by the pins 48 and 50 coincides withthe center of mass of the armature 18 so that this armature isdynamically balanced to prevent undesired movement due to shock andacceleration, for instance. The pin 48 is received within an openingformed in a bossed portion 52 of the frame 16 which provides a bearingsurface engaging the outer surface of the armature 18. The pin 50 isreceived within an opening 54 (FIGS. 2, 4 and formed in a lug 56 whichis formed integral with a side wall of the frame 16. In the releasedcondition of the relay 10, the armature 18 is resiliently biased to theposition shown in FIG. 3 by a spring 58 having a convolute bight portionencircling the pin 50; a first offset end portion 58a which engages thelug 56, and a second offset end portion 581) which bears against oneside of the armature 18.

The contact assembly 20, which is actuated by the armature 18 when therelay is operated, includes two similar form 0 contact assembliescarried on the header plate 22 adjacent opposite ends of the armature18. Each of these assemblies comprises a pair of generally V-shapedcontact springs 60* and 61 (FIG. 2) carried on a pair of terminal pins62 and 64 and an elongated transfer spring 66, one end of which iscarried on a terminal pin 68. The terminal pins 62, 64 and 68 are sealedwithin spaced openings in the header plate 22. The transfer springs 66are so positioned as to normally engage the break springs 60 so that,upon operation of the relay 10, the springs 66 are moved out ofengagement with the break springs 60 and into engagement with the makesprings 61. The header plate 22 also supports a pair of terminal pins 70to which the leads to the coil '32 are connected.

To provide means for actuating the contact assembly 20, the oppositeends of the armature 18 are provided with a pair of depending arms 72and 74, the free ends of which are embedded in dielectric beads 76 and78, respectively. The dielectric beads 76 and 78 on the actuator pins 72and 74 are disposed in opposite sides of the two transfer springs 66 sothat, when the armature 18 is pivoted in a clockwise direction (FIG. 3),these beads move into engagement with the free ends of the transfersprings 66 and move these springs relative to the springs 60 and 61. Theactuator arms 72 and 74 are preferably secured to the opposite ends ofthe armature 18 by welding and are each provided with an ofiset endportion, such as a portion 72a (FIG. 2), which is adapted to engage theframe 16 when the armature 18 is biased to its normal position by thespring 58, thereby to limit counterclockwise movement of the armature18.

In operation, when the winding 32 is energized by an operating signal ofany polarity, the flux field induced by the coil 32 passes along thecore elements 36 and 38 to one of the pole pieces or enlarged portions36a and 38a, passes across the air gap to one of the recessed portions184; and 18b on the armature 18, and then returns to the core assembly14 through the armature 18 and the air gap formed between the other ofthe pole pieces 36a and 38a and the other of the recessed portions 18aand 18b. The force produced by this flux field pivots the armature 18 ina clockwise direction (FIG. 3) against the action of the spring 58 sothat the recessed portions 18a and 18b of the armature 18 move intoengagement with the pole pieces afforded by the enlarged portions 36aand 38a of the core elements 36 and 38. In moving to this position, thedielectric beads 76 and 78 carried on the ends of the actuator arms 72and 74 move into engagement with the free end portions of the transfersprings 66 so that these springs are moved out of engagement with thebreak springs 60 and into engagement with the make springs 61.

When the energizing signal is removed from the winding 32, the spning 58rotates the armature '18 in a counterclockwise direction (FIG. 3) sothat the recessed portions 18a and 18b of the armature 18 move away fromthe pole pieces provided by the enlarged portions 360: and 38a. Duringthis movement, the dielectric beads 76 and 78 carried on the ends of theactuator arms 72 and 74 move out of engagement with the transfer springs66 so that these springs, by their own resiliency, move out ofengagement with the make springs 60 and into engagement with the breaksprings 61. This counterclockwise deflection of the armature 18 isarrested by engagement of the offset ends of the arms 72 and 74 with theinner surface of the frame 16.

Accordingly, the relay 10 of the present invention includes new andimproved means for removably mounting the coil assembly 12 on thesupporting frame 16 by the use of the core assembly 14. The coreelements 36 and 38 not only serve .to properly locate the coil assembly12 in a proper position on the supporting frame 16 but also provide polepieces toward which the armature 18 is moved by the enengizati'on of theoperating winding 32.

Although the present invention has been described in conjunction with asingle embodiment thereof, it will be apparent that numerous othermodifications and changes may be made by those skilled in the art whichwill fall within the spirit and scope of the principles. of thisinventlon.

What is claimed as Letter Patent of the l. A relay constructioncomprising a coil structure defining an axially extending passageway; aframe having a pair of spaced end walls each defining an opening; afirst core element mounted in said openings and passing through saidpassageway, said first core element having an enlarged portion disposedbetween one of said end walls and one end of said coil structure toprovide a first pole piece; and a second core element mounted in saidopenings and passing through said passageway parallel to said first coreelement, said second core element having an enlarged portion disposedbetween the other of said end walls and the other end of said coilstructure to provide a second pole piece.

2. A relay construction comprising a coil bobbin having a pair of spacedend plates joined by a hollow element defining a substantiallyrectangular opening; -a winding on said bobbin; a frame structureincluding a pair of spaced end walls, each of said end walls defining apair of adjacent slots of a first length and of a second length lessthan said first length; a first core element slidably mounted in saidopening and having one end disposed in the slot of said second length inone of said end walls, said first core element also including anenlarged portion disposed in the slot of said first length in the otherof said end walls and abutting one of the end plates on said bobbin; anda second core element slidably mounted in said opening parallel new anddesired to be secured by United States is:

to said first core element and having one end disposed in the slot ofsaid second length in said other end wall, said second core element alsoincluding an enlarged portion disposed in the slot of said first lengthin said one end wall and abutting the other end plate of said bobbin.

3. The relay construction set forth in claim 2 including an armaturepivotally mounted on said frame with spaced portions of said armaturedisposed adjacent the enlarged portions on said first and second coreelements.

4. A relay construction comprising a coil structure defining an axiallyextending passageway; a frame structure including a pair of spacedwalls, each of said walls having a pair of contiguous slots formedtherein; and a pair of core elements slidably mounted in a parallelrelation in said passageway and in the pairs of slots in said spacedwalls to provide the sole means for supporting said coil structure onsaid frame structure, said core elements including enlarged portions.positioned at opposite ends of said coil structure to locate theposition of said coil structure on said frame structure.

5. A relay construction comprising a coil structure having an axiallyextending opening, a frame structure including a pair of spaced walls, apair of core elements for mounting said coil structure on said framestructure, each of said core elements having an enlarged pole pieceportion, said core elements being mounted on said walls and beinginserted into said axially extending opening from opposite ends of saidcoil structure so that said enlarged pole piece portions are disposed atthe opposite ends of said coil structure to both mount said coilstructure on said frame structure and provide spaced pole pieces atopposite ends of said coil structure.

6. A relay construction comprising a frame including a pair of spacedsupporting elements each having an opening therein, a coil structurepositioned between said supporting elements and having first and secondend walls and an axial opening extending between said walls, a pair ofcore elements each having an enlarged portion extending generallytransverse to the length of the core element, a first one of said coreelements being inserted through the opening in one of said supportingelements into said axial opening so that the enlarged portion on saidfirst core element engages said first wall, a second one of said coreelements being inserted through the opening in the other of saidsupporting elements into said axial opening so that the enlarged portionon said second core element engages said second wall, said first andsecond core elements supporting said coil structure on said frame, andla movably mounted armature including two spaced portions eachpositioned adjacent one of said enlarged portions.

7. A relay construction comprising a coil structure having an axiallyextending opening, a frame structure including a pair of spaced andgenerally parallel walls, each of said pair of walls including a slotaligned with the slot in the other wall, a pair of core elements formounting said coil structure on said frame structure, each of said coreelements having an enlarged pole piece portion, said core elements beingmounted in the slots on said walls and being inserted through said slotsinto said axially extending opening from the opposite ends of said coilstructure with said enlarged pole piece portions disposed at theopposite ends of said coil structure so that said core elements bothmount said coil structure on said frame structure and provide spacedpole pieces at the opposite ends of said coil structure.

8. The relay construction set forth in claim 7 in which said coreelements include flat and generally uniplanar portions disposed in acontiguous parallel relation within said axially extending opening.

9. A relay construction comprising a coil structure having an axiallyextending opening, a frame structure including a pair of spaced andgenerally parallel walls, each of said pair of walls including a slotaligned with the slot in the other wall, a pair of core elements formounting said coil structure on said frame structure, each of said coreelements having an enlarged pole piece portion extending generallytransverse to the length of the core element, one of said core elementsbeing inserted through the slot in a first one of said walls and throughsaid axially extending opening to be received in the slot in a secondone of said pair of walls so that the pole piece portion on said firstcore element is disposed adjacent said first wall, a second one of saidcore elements being inserted through the slot in said second wall andthrough the axially extending opening to be received in the slot in saidfirst wall so that the pole piece portion on said second core element isdisposed adjacent said second wall, said core elements serving both tomount said coil structure on said frame structure and to provide spacedpole pieces at the opposite ends of said coil structure, and movablymounted armature means including spaced portions disposed adjacent thetransversely extending pole piece portions on said core elements.

10. The relay construction set forth in claim 9 in which said coreelements include fiat and generally uniplanar portions disposed in acontiguous parallel relation within said axially extending opening.

11. A relay construction comprising a coil structure including a coilbobbin with first and second bobbin end walls connected by a portiondefining an opening; a unitary supporting frame structure of generallyrectangular configuration having apertured front and back walls, an openbottom, and spaced and generally parallel side walls, said side wallseach having a slot therein generally aligned with the slot in the otherside wall, said coil structure being disposed within the generallyrectangular frame structure with the opening generally aligned with theslots in the side walls; a pair of core members for mounting said coilstructure on said frame structure, each of said core members having anenlarged pole piece portion extending generally transverse to the lengthof the core member, a first one of said core members being insertedthrough the slot in a first one of said side walls and through saidopening so that the pole piece portion on the first core member engagesthe first bobbin end wall and is disposed between the first bobbin endwall and the first side wall, the second one of said core members beinginserted through the slot in the second side wall and through theopening so that the pole piece portion on the second core member engagesthe second bobbin end wall and is disposed between the second bobbin endwall and the second side wall, said core members serving both to mountsaid coil structure on said frame structure and to provide spaced polepieces at the opposite ends of the coil structure; armature meansincluding spaced portions extending upwardly adjacent the transverselyextending pole piece port-ions on the core members; and means includinga lug projecting inwardly from one of the front and back walls of theframe structure adjacent the lower end of the aperture therein forpivotally mounting said armature means on said frame structure.

12. The relay construction set forth in claim 11 including a headerplate secured to the lower end of the frame structure to close the openbottom and disposed below the armature means; contact means carried onthe header plate and disposed below the armature means, said contactmeans including a pair of contact springs each having a free end portiongenerally aligned with and disposed below one of the pole pieceportions; and two spaced means depending from and secured to thearmature means at points aligned with the pole piece portions forengaging and operating the free end portions of the con tact springs.

13. The relay construction set forth in claim 5 including pivotallymounted armature means having a central portion disposed below said coilstructure and end portions extending upwardly from said central portionadjacent the pole piece portions on the core elements, contact meansdisposed below said armature means and in- References Cited in the fileof this patent eluding two contact springs each having a free end por-UNITED STATES PATENTS tion positioned generally below one of the polepiece por- 1 104 077 T Smith July 21 1914 tions, and two means eachsecured to and depending from 1273820 giiiiiiii': July 1918 the armaturemeans at spaced points generally aligned .5 1:991:210 Henderson et a1.Feb 1935 with the pole piece portions and the end portions of the2,436,354 Burke et aL Feb; 17 1943 armature means for engaging andactuating the free end 2 71 5 gamers Sept 20 55 portions of the contactsprings. 2,923,794 Keeran Feb. 2, 1960

1. A RELAY CONSTRUCTION COMPRISING A COIL STRUCTURE DEFINING AN AXIALLYEXTENDING PASSAGEWAY; A FRAME HAVING A PAIR OF SPACED END WALLS EACHDEFINING AN OPENING;A FIRST CORE ELEMENT MOUNTED IN SAID OPENINGS ANDPASSING THROUGH SAID PASSAGEWAY, SAID FIRST CORE ELEMENT HAVING ANENLARGED PORTION DISPOSED BETWEEN ONE OF SAID END WALLS AND ONE END OFSAID COIL STRUCTURE TO PROVIDE A FIRST POLE PIECE; AND A SECOND COREELEMENT MOUNTED IN SAID OPENINGS AND PASSING THROUGH SAID PASSAGEWAYPARALLEL TO SAID FIRST CORE ELEMENT, SAID SECOND CORE ELEMENT HAVING ANENLARGED PORTION DISPOSED BETWEEN THE OTHER OF SAID END WALLS AND THEOTHER END OF SAID COIL STRUCTURE TO PROVIDE A SECOND POLE PIECE.